Apparatus and process for manufacturing of pile fabric



Nov. 17, mm LO ETAL 3,540,098

APPARATUS AND PROCESS FOR MANUFACTURING OF PILE FABRIC Original FiledApril 1, 1965 4 She etsSheet 1 FIG. 20

, v n llb INVENTORS SIEGFRIED PLOCH WALTER SCHOLTIS HEI NZ ZSCHUNKE Nov.17, 1970 PLOCH ET AL 3,540,098

APPARATUS AND PROCESS FOR MANUFACTURING OF PILE FABRIC 4 Sheets-Sheet 3Original Filed April 1. 1965 M MU FIG. 5 i- 'IM'Il/IIIII'III FlG. liaFIG. 7b

INVENTORS SIEGFRIED PLOCH WALTER SCHOLTIS HElNZ ZSCHUNKE NOV. 17,1970 5PLQCH ETAL A 3,540,098

APPARATUS AND PROCESS FOR MANUFACTURING OF FILE FABRIC Original FiledApril 1, 1965 4.Sheets-Sheet C5 FIG. 7e

mumuum W INVENTORS SlEG FRIED PLOCH WALTER SCHOLTIS HElNZ ZSCHUNKE Nov.17,1970 3. PLOCH ET AL APPARATUS AND PROCESS FOR MANUFACTURING OF FILEFABRIC OriginalFiled April 1. 1965 4: Sheets-Sheet 1 STITCHING FIBERS OFWEB TO BACKING SHRINKING TREATMENT Thqll.

FEEDING BACKING AND FIBROUS WEB TO WORK POSITION STITCHING FIBERS OF WEBTO BACKING SHEARING THE PLEATED WEB INVENTORS SIEGFRIED PLOCH WALTERSCHOLTIS HEINZ ZSCHUNKE ATTORNEYS United States Patent 01 3,540,098Patented Nov. 17, 1970 3,540,098 APPARATUS AND PROCESS FOR MANUFACTUR-ING F PILE FABRIC Siegfried Ploch, Walter Scholtis, and Heinz Zschunke,

Karl-Marx-Stadt, Germany, assignors to Forschungsinstitut furTextiltechnologie, Karl-Marx-Stadt, Germany Original application Apr. 1,1965, Ser. No. 444,640, now Patent No. 3,442,101, dated May 6, 1969.Divided and this application Apr. 26, 1967, Ser. No. 649,386 Int. Cl.D04b 23/10 U.S. Cl. 28-72 26 Claims ABSTRACT OF THE DISCLOSURE Anapparatus and method is disclosed for use in manufacturing a textile webfrom a base and a fiber layer. The fiber layer is fed adjacent the baseand reciprocating needles carried by a knitting machine form fiber loopsfrom the fiber layer which loops are subsequently returned through thebase to interconnect the base and fiber layer to form the textile web.

This application is a divisional application of application, Ser. No.444,640, filed Apr. 1, 1965. Said application has now issued as US. Pat.No. 3,442,101.

The present invention relates to textile webs which have a fiber layerarranged on a base or foundation, as well as to a device and process forjoining the base with the fiber layer by means of parallel seams offiber loops extending in the direction of movement of the web throughthe device.

It is known to sew fleeces to a base web with the aid of sewing threads.This results in insufficient properties for use as the fibers are notanchored firmly enough in the fabric bond. Moreover, because of thesewing threads, an additional thread system is required.

Another known process envisages the needling up of fleeces on a basewith the aid of multi-needle machines having needles with small barbs.These needles penetrate from the side of the fleece through the twomaterials to be joined and on their return take along a number of fibersas, for example, in the form of fiber loops. These loops are put down onthe top side of the fleece in a quilting stitch manner and compress thefleece in an unwanted manner. The fleece is connected with the base onlyby those fibers which have been pulled through to the side opposite thefleece and which form little knots thereat. The connection between thefleece and the base is not very strong.

In another known process, fiber tufts are bound into knit fabrics,simultaneously with the production thereof, by means of circularknitting machines. For this purpose the machine has on its circumferencebetween four and eight miniature cards to which a fiber band issupplied, and which deliver the fibers coming from the band into theneedles of the knitting machine. The output of this type of machine isrelatively low, the resulting product has at first the property of amesh fabric which must subsequently be stabilized by subsequentfinishing. Moreover, with such machines only the connection betweenfiber tufts and a knit fabric is possible, while the sewing in of thefiber tufts, for example, in foam material or fleece fabric webs cannotbe accomplished by this method.

Methods are also known for gluing pleated fleeces on a base or betweentwo base webs. The disadvantages of this method are that an adhesive isneeded, that the product becomes rather stiff, and that the airpermeability and hence the respiratory activity of the product areimpaired by the gluing.

Finally, it is known to sew fleeces in the form of longitudinal ribs ona base web by means of nap-forming elements. Sewing threads are againneeded, and the fibers are held only by the pressure between sewingthreads and base web so that they are not firmly anchored in the baseitself.

It is the object of this invention to provide a textile web in which afiber layer is connected with a base or foundation without sewingthreads, providing high strength, without constricting the fiber layerin the manner of a quilting stitch seam; as well as a device and aprocess for making this novel web.

According to an important feature of the invention, the backing or thebase and the fiber layer are connected by means of fiber loops which arepulled out of the fiber layer and formed into Wales or chain-stitchseams and arranged on the back of the base or foundation. The fibers areoriented in the fiber layer, preferably lengthwise or transverse to thedirection of movement of the web.

The backing or base is a Woven, knitted, fleece, foam material orsimilar web. Alternatively, it may be formed of a loose layer oflongitudinal and/or transverse threads. The transverse and longitudinalthreads are arranged in crossed superposition and are mutuallyinterconnected by means of the fiber loops pulled out of the fiberlayer, and finally connected with the fiber layer itself.

In the process for the production of the textile web, according to theinvention, the fiber loops are pulled out of the fiber layer by means ofslide, latch, or other suitable reciprocating needles of multi-needlemachines.

In the inventive device, the fiber layer is pushed into the hooks of theneedles by suitable means, e.g. by way of a roller fitted completely orpartly with brushes. The roller rotates continuously or synchronouslywith the needles, by means of a rod or rail executing a swingingmovement synchronously with the needle cycle. The roller may be fittedwith brushes, or by a similarly functioning pressure rod which may alsobe designed in the form of a pressure comb.

The tips of the needles enter into the fiber layer from the side of thebase, pull the seized fibers through the base on their return, and formfrom these fibers, a fiber loop held by the needle hooks. As has beenmentioned, the backing or base may consist of a woven, knitted, fleece,or foam material, or a layer of longitudinal or transverse threads orfibers, or of loosely superimposed longitudinal and transverse threads.

When the needles occupy their rearmost position and their hooks areclosed, the previously formed fiber loops still present on the needleshanks are cast off over the previously mentioned new fiber loops. Inthis way a portion of the fiber material is present as wales or chainstitch seams on the side of the base away from the fiber layer, and thusestablishes a firm connection between the fiber layer and the base. Thisconnection is much more intimate due to its mesh-like, non-ravelingarrangement than can be achieved with the known needling.

The fibers may also be pulled out of the fiber layer in such manner sothat separate fiber tufts are formed which are tied into the base-likeknitting stitches. The fiber tufts result in a plush-or fur-likesurface. By increasing the rate of supply of the fiber layer in relationto that of the base web about four to tenfold, the fiber layer can becompressed in transverse direction or even pleated in rib form.

By the use of nap-forming or pile forming means, e.g. nap sinkers orloop formers, between the needles of the novel device, an arrangement inthe form of longitudinal ribs can be obtained.

The fiber layer of the textile web according to the invention may alsoconsist of two or more fiber layers, the fibers in the layer toward theneedles being, for example, substantially longitudinally oriented, whilethe fibers in the outer layer are oriented substantially slantwise tothe direction of movement of the web. Then substantially only thetransversally oriented fibers are seized by the needle hooks and bindthe longitudinally oriented fibers in, together with the above-mentionedloose fiber layers.

The textile web according to the invention can be finished in variousways, for example, it is possible to roughen it, shear it, or full it.The base and/or the fiber layer may consist wholly or partly ofshrinkable fiber materials, known per se. The textile web thus producedcan then be subjected to a shrinkage treatment resulting in athickeningof the fiber layer.

The advantages of the textile web, process and device according to thepresent invention are the following. The connection of the fiber layerwith the base is achieved without sewing thread but with substantialpreservation of the voluminosity of the fiber layer, from which a rough,high pile, or similar surfaces can be achieved in a particularlyfavorable manner. There are no quilting-seam type constrictions. Also,the nap formation itself occurs without the use of spun products orthreads, using only the fibers of the fiber layer, so that for this partof the textile web the spinning process and the preparatory operations,such as reeling and warping, are also eliminated.

No special machines are necessary, as the device required for carryingout the process, for feeding the fiber layer and for introducing thefibers into needle hooks, is relatively simple and can easily beattached to known rnulti-needle machines. For the production of thetextile web according to the invention there is used a multineedlemachine which in its output is superior to the known looms and knittingmachines.

The invention permits the manufacture of a plurality of products, suchas velours, padded overcoat materials, blankets, fur imitations,plushes, and carpets.

The products according to the invention have a high voluminosity as thefiber material is not pressed into a.

spun system. Thereby major air inclusions are obtained, which result ina higher heat holding capacity than with the use of yarns or compressedfleeces. Due to the fact that the proportion of fibers taken along onthe side of the base away from the fiber layer can be controlled, abilateral arrangement of a fiber layer on the base is obtained, thefibers being present on one side in fleece, nap, or tuft form and on theother side side in the form of knitted stitches. Depending on thequantity of fibers participating in the stitch formation, the stitchside, too, can be given a plush-or blanket-like finish.

The control of the proportion of fibers of the fiber layer formed intostitches can be effected in the inventive process and device, amongother things, by the size of the needle hooks, by the timing of thecovering of the needle hooks inside or outside the fiber layer, by theregulation of the speed and amount of movement of the means for pressingthe fiber layer into the needle hooks, by the height of the nap or plushsinkers, by the mass of the fiber layer, and by the rate of their feed.

Other objects and advantages of the invention will be appreciated andmore fully understood with reference to the following detaileddescription, when considered with the accompanying drawings, whereinFIG. '1 is a somewhat schematic, cross-sectional view of a work positionof the device according to the invention, forming part of a multi-needlesewing-knitting machine, with slide needle, brush roller and fabricfeed;

FIGS. 2a and 2b illustrates a tubular and latch needle, respectively,which can also be used in the inventive device;

FIG. 3 is a view similar to that of FIG. l of an alternative deviceaccording to the invention, having a brushfited rod or rail therein;

FIGS. 4a and 4b show a pressure rod and a pressure 4 comb, to be used inthe inventive device in lieu of brushes as shown in FIG. 3;

FIG. 5 is a plan view of the drive for the needles, the closing wiresand also for the brush-fitted rail of FIG. 3;

FIG. 6 is a partial sectional view of the drive shown in FIG. 5, takenalong line 66;

FIGS. 7a-7d shows, in longitudinal sectional views, various forms oftextile webs made according to the invention, with the devices of FIGS.1 and 3, and having a woven fabric as a base;

FIG. 7e is a plan view of the textile web according to FIG. 7d;

FIG. 8 is a view similar to that of FIGS. 1 and 3 of another alternativedevice using an array or layer of longitudinal and transverse threads asa base,

FIG. 9 is a longitudinal sectional view, similar to those of FIGS. 7a7d,of a textile web produced with the device of FIG. 8,

FIG. 10 is a block diagram illustrating one process for making a pilefabric according to the invention, in which the backing is subjected toa shrinkage treatment; and

FIG. 11 is a block diagram illustrating another process for making apile fabric according to the invention, in which the fabric is subjectedto a shearing treatment.

FIG. 1 of the drawings shOWs a first embodiment of the work position ofthe device according to the invention, forming part of a multi-needleknitting machine also capable of sewing stitches. As shown in thesomewhat schematic view, the device comprises a plurality of slideneedles 11 arranged on a common bar 21, the needles having hooks 11a(see the enlarged views of FIGS. 2a and 2b). For closing the hooks,wires 12 are provided on a bar 22. The conventional means serving toreciprocate the needles 11 and the closing wires 12 have not beenillustrated; reference to an appropriate drive mechanism will be madewhen describing FIGS. 5 and 6.

This type of device uses a woven fabric as a base, shown at 60, to whichis applied a fiber layer 70, as will be explained in more detail. Thislayer preferably consists of fibers oriented substantiallylongitudinally or transversally to the direction of advance. The exit ofthe slide needles 11 from the base 60 is ensured by cast-off sinkers 13,secured to a bar 23. The fiber layer is laid over pile loop formers, napor plush sinkers 14 supported by a bar 24.

The fabric 60, serving as a base, is fed continuously to the device, asis the fiber layer 70. The latter is continuously delivered by means ofrotating feed rollers 18, one of them entraining an endless conveyorcloth 28 which also passes over a roller 19 in the region of the workstation. The fiber layer 70 may, however, also be fed directly to thesewing-knitting station by a card (not illustrated) workingsynchronously with the machine.

The slide needles 11 pass through the base 60 and seize with their hooks11a fiber tufts from the fiber layer 70, when they have reached theirforemost position (as illustrated). The fiber layer 70 is brought intothe form of nap-like longitudinal ribs by the co-operation of thesinkers or loop formers 14. The fibers are pushed into the hooks 11a ofthe needles 11 by a rotating brush roller 20 so that the needles, ontheir return, take along the fiber tufts from the fiber layer 70,pulling them through the base 60.

In the hooks 11a of the slide needles 11 these fiber tufts form fiberloops over which the previously formed fiber loops are cast off in therearmost position of the needles when their hooks 11a are closed by thewires 12. There are thus formed closed wales or chain-stitch seams, andthe reverse side of the textile Web according to the invention has theappearance of a mesh fabric, as will be explained further as thedescription proceeds.

Instead of the previously made woven or other type of base fabric asshown at 60, a knit, a fleece, or a foamed web may be used with thedevice illustrated in FIG. 1.

It should be noted that instead of the slide needles 11 shown in FIGS.1, 3 and 8, tubular needles 11' or latch needles 11" may be used (seerespective FIGS. 2a and 2b). In the former, a closing member 1112 mayslide back and forth for opening the hook 11a. In the latter, a latch11c is provided in a known manner for the same purpose. It is understoodthat the afore-mentioned closing wires 12 are adapted to co-operate withthe alternative types of needles as well.

FIG. 3 shows an alternative or second embodiment of the device accordingto the invention, wherein most elements are identical with those alreadydescribed for FIG. 1, and have, accordingly, been given identicalreference numerals. Instead of the previous rotating brush roller 20,however, this device has a rod or rail 50 which carries a plurality ofsmall brushes 40. The rail 50 is made to carry out an up-and-downswinging movement in unison with the longitudinal reciprocation of theneedles 11, as indicated by the appropriate arrows.

Instead of brushes, rail 50 may carry a pressure rod 40' as shown inFIG. 4a or a pressure comb 40", as illustrated in FIG. 4b. The rod 40 ispreferably equipped with a foam or rubber covering (not shown). Itshould be noted that both the rail 50 and the needle bar 21 may beprovided with appropriate, conventional holders for releasableattachment of the respective brushes and needles, as has beenschematically shown in FIG. 5.

FIGS. 5 and 6 illustrate an exemplary embodiment of the drive mechanismfor the needles 11, the wires 12 and particularly for the brush rail 50of the device of FIG. 3. It should be noted that this drive mechanismhas been shown in FIGS. 4 and 5 of US. Pat. 3,030,786 to H.Mauersberger, with a reissue patent Re. 25,749 dated Mar. 23, 1965,entitled Textile Material and Manufacture, and co-assigned with thepresent application. In the present FIGS. 5 and 6, correlated referencenumerals have been used (e.g. 111 instead of 11, or 150 instead of 50 asused in the earlier patent).

The drive mechanism employs, for purposes of rapid machine operation,circular eccentric cams for actuating the needles 11, the closing wires12 and the brushes 40. As shown in FIG. 5, the needle bar 21 carryingthe needles 11 is actuated by a connecting rod 113 extending from aneccentric rod 112 linked to a strap 112a of an eccentric cam 111 whichis rotated by a motor-driven shaft 110 supported by a housing 150.

Similarly, the recriprocating movement of the closing wires 12 isobtained by means of an eccentric cam 115 cooperating with a strap 142aactuating, through an cecentric rod 142, a connecting rod 143 thatactuates the bar 22 which carries wires 12. The connection between rod143 and bar 22 has been broken away for the sake of clarity.

The rail 50, carrying brushes 40, is fixedly mounted on a shaft 120 bymeans of suitably attached lever arms 117. Shaft 120, being rotatablymounted within bearings 119, is adapted to slide longitudinally back andforth, within certain limits, and carries a short lever 121. The latteris connected with a coupling rod 122 linked to an eccentric rod 124.This rod, with its strap 124a, encloses an eccentric cam 125 which, bymeans of an intermediate connecting rod 123, moves the brushes 40 up anddown.

Aside from this reciprocating movement, the brushes must preferablyundergo an axially transverse back and forth movement. The brushes 40and the shaft 120 carrying the rail 50 therefore are preferably operatedto perform one complete back and forth movement while the needles 11 aremoved twice back and forth. To accomplish this, a pinion 126 keyed tothe shaft 100 engages a spur wheel 127 of twice its size. Consequently,the spur wheel rotates at one half of the speed of the shaft.

The spur wheel 127 is fixedly connected with an eccentric cam 128 whosestrap member 129a is lined by an eccentric rod 129 to a connecting rod131, axially slidable in bearing 130. When in operation, the rod 131 andits linkage 131a impart axial reciprocation to the shaft 120 byactuating an angle lever 133 rotatably mounted on a pivot 132. A tensionspring 134 positioned around the shaft between one of the bearings 119and the adjacent lever arm 117 of the rail 50 aids the axiallyoscillating movement by forcing the shaft against an adjusting screw 135connecting the free end of angle lever 133 to that of shaft 120.

In carrying out the new textile-web making process according to thepresent invention, the fibers of layer 70 may be given a much greaterlength than that consumed in each working cycle, so that they are seizedseveral times in succession by the needles, namely successively byseveral needles standing side by side, owing to the lateral movement ofrail 50, as has been described before. This results in lockedchain-stitch seams which solidly connect the fiber layer 70 with thebase 60, and which do not unravel.

FIGS. 7a through 7d show various longitudinal sections of textile websmade according to the invention, with FIG. 7e representing a plan viewof the web according to FIG. 7d. These variants can be produced with thedevices according to FIGS. 1 and 3. In the alternative of FIG. 7a, thebase 60 is connected with a closed fiber layer 70a by means of the fiberloops 75 as shown in FIG. 7a the fiber loops 75 are substantiallyU-shaped in form and adjacent loops are interconnected together at theside base or backing 60 disposed away from fiber layer 70a. In thismanner fiber layer 70a is firmly secured to base 60.

In the second alternative according to FIG. 7b, separate twistless fiberbundles 90 are pulled out of the plush fiber layer 70b, fed to theworking station in closed form. These bundles are anchored in the base60 by means of the substantially U-shaped fiber loop 75. The legportions of the loops 75 are passed through a single opening in base 60.Adjacent loops 75 are interconnected to one another to thereby securethe fiber layer 70b to the base 60. The fiber bundles or tufts 90extending uniformly throughout fiber layer 7 0b, form a plushor fur-likeWeb surface.

In the form of web shown in FIG. 70, a crosswise pleated fiber layer 700is utilized, that is the twistless fibers of layer 700 are folded overone another to achieve a greater thickness of fiber as shown in FIG. 70,the pleatmg bemg crosswise to the direction of movement of the web. Thelayer is connected with the base 60 by means of the loops 75. Thepleating has been obtained in that the fiber layer 70 has been fed tothe device at a speed increased by about four to tenfold as compared tothe fabric base 60.

In the fourth alternative appearing in FIGS. 7d and 7c,

the fiber layer connected with the base 60 by means of loops 75 consistsof two layers, namely 70d and 70d. The fibers in layers 70d are orientedsubstantially in the direction of movement of the Web, while the fibersin layer 70d are oriented substantially perpendicularly thereto. In theplan view of FIG. 7e the stitch lines in course 70d are indicated by thebroken line 75'. modified or third embodiment of the inventive device isillustrated in FIG. 8 wherein, again, identical elements have beendesignated with the same numerals as in FIGS. 1 and 3. This devicepermits the use of loose longitudinal and transverse threads or fibersin crossed superposition, instead of woven or knitted fabrics or thelike, as a base fabric 60' for the novel textile web. Such a base 60' isillustrated as consisting of cross threads 61, supplied continuously tothe device by means of endless needle chains 62. Longitudinal threads 63are continuously fed, in the manner of a warp-thread group, in a mannerto be described somewhat later.

Closing wires 12' have been alternatively illustrated, secured to bar22, which are somewhat different from the wires 12 of the previousembodiments. Cast-off sinkers 13' are provided on bar 23, somewhatlonger than sinkers 13 illustrated and described before. Additionally,the device of FIG. 8 is fitted with counter-holders 15 held by a commonbar 25, and a counter-holder rod 16. As clearly shown in the drawing,the fiber layer 70 is guided between these last-named elements. Forintroducing the warp-wise threads 63, eye needles 65 are providedbetween the counter-holders 15 and the path of the layer 70; theseneedles are also held by the bar 25. V

The device operates as those described before. By means of the feedrollers 18 and the conveyor cloth 28, driven by one of the feed rollersand guided around roller 19, the fiber layer 70 is supplied continuouslyto the work position of the machine. The feed of the fiber layer may,however, also be effected directly by a card (not illustrated) workingsynchronously with the sewing-knitting machine.

When the needles 11 have reached their foremost position, asillustrated, the fibers of layer 70' are pushed, by the rotating brushroller 20, into the hooks 11a of the nefedles. On their return, theneedles take along these fiber tu ts.

In the hooks 11a, the fiber tufts form fiber loops 75 over which thepreviously formed fiber loops are cast off by means of sinkers 13' inthe rearmost position of the needles 11, in which the hooks are closedby the wires 12. The cast-off sinkers 13 ensure, moreover, the exit ofthe needles 11 in their rearmost position from the layer 70 and the baselayer 60 (including threads 61 and 63). The counter-holder 15 and thecounter-holder rod 16 facilitate the passage of the needles 11 duringtheir forward move ment through the threads 61, 63 and fiber layer 70.

It will be understood, of course, that needles 11 and 11" might as wellbe used in this embodiment of the inventive device, too. Also,alternately, individual brushes 40 on a bar 50 could be incorporatedinstead of the rotating brush roller 20.

FIG. 9 shows a textile web made with the use of the device of FIG. 8,utilizing threads as a base or foundation. The transverse threads orfibers 61 and the longitudinal threads 63 constitute the base 60'; theyare connected with the fiber layer 70 by way of fiber loops 75. Itshould be noted, however, that the connection of the layers can also beeffected in the manner shown in FIGS. 7b through 7d.

According to the invention, as illustrated in FIGS. 10 and 11, thetextile web can be finished in various ways. As illustrated in FIG. 10,after the backing and fibrous web have been placed into the workposition, and the fibers of the web stitched to the backing inaccordance with the above described techniques for making a pile fabric,the fabric may be subjected to a shrinkage treatment to increase thethickness of the fiber layer. In this event, the backing and/ or fiberlayer may consist wholly or partly of known shrinkable materials. Asillustrated in FIG. 11, the pile fabric may be sheared following thestitching of the fibers of the web to the backing, in order, forexample, to produce an even pile layer.

The foregoing disclosure relates only to preferred, exemplaryembodiments of the invention, which are intended to include all changesand modifications of the examples described within the scope of theinvention.

We claim:

1. A device for manufacturing pile fabric from a backing and a fibrousweb comprising:

(a) a plurality of knitting needles having hooks thereon reciprocablealong a path;

(b) a plurality of pile loop formers located adjacent said knittingneedles, said formers being spaced to permit said needles to passtherebetween during a portion of their reciprocation and having a gapbetween one edge of said formers and the ends of said needles when saidneedles are at one end of said path;

() means for feeding a backing through said gap;

((1) means for feeding a fibrous web to the edge of said formersopposite to said one edge;

(e) means for reciprocating said needles to the other end of said pathto penetrate said backing and said spaces between said formers and topenetrate said web; and

(f) means moving in an arcuate path for pushing portions of said fibrousweb into said needle hooks whereby said portions of said web are drawnby said needles between said formers and through said backing to formpile loops of said web about said formers on one side of said backingand knitted stitches on the other side thereof upon reciprocation ofsaid needles to said one end of said path.

2. A device according to claim 1, wherein said pushing means comprises amember having bristles thereon and wherein the number of said bristlessubstantially exceeds the number of said plurality of needles.

3. A device as set forth in claim 1 wherein said means for pushingportions of said fibrous web into said needle hooks comprises resilientbristles.

4. A device as set forth in claim 3 wherein said pushing means furthercomprises a roller having said resilient bristles thereon.

5. A device as set forth in claim 3 wherein said pushing means furthercomprises a bar with said resilient bristles thereon.

6. A device as set forth in claim 1 wherein said pushing means comprisesa pressure rod member.

7. A device as set forth in claim 6 wherein said pressure rod member hasa toothed portion.

8. A device as set forth in claim 1 wherein said means for feeding saidbacking comprises endless chain means for feeding a plurality of spacedyarns through said gap.

9. A device as set forth in claim 1 wherein said pile loop formerscomprise a plurality of stationary fingers wherein said fibrous web isformed into loops, said loops sliding off the end thereof as saidbacking moves through said gap.

10. A device as set forth in claim 1 wherein said web feeding meanscomprises means for feeding said web at a faster rate than said backingso as to form lateral pleats in said web.

11. A device as set forth in claim 1, wherein said plurality of needlesare arranged in a row and further including means for displacing saidpushing means in a direction perpendicular to the movement of saidneedles and longitudinally of said row of needles.

12. A device as set forth in claim 11 further including means fordisplacing said pushing means in a direction perpendicular to saidneedle movement in timed relation with said needle movement.

13. A device as set forth in claim 11 wherein said pushing meanscomprises a pressure rod member.

14. A device as set forth in claim 13 wherein said pressure rod memberhas a toothed portion.

15. A device as set forth in claim 11 wherein said means for feedingsaid backing comprises endless chain means for feeding a plurality ofspaced yarns through said gap.

16. A device as set forth in claim 11 wherein said pile loop formerscomprise a plurality of stationary fingers whereon said fibrous web isformed into loops, said loops sliding off the end thereof as saidbacking moves through said gap.

17. A device as set forth in claim 11 further comprising means forfeeding said web at a faster rate than said backing so as to formlateral pleats in said web.

18. A device as set forth in claim 11 wherein said means for pushingportions of said fibrous web into said needle hoops comprises resilientbristles.

19. A device as set forth in claim 18 wherein said pushing means furthercomprises a roller having said resilient bristles thereon.

20. A device as set forth in claim 18 wherein said pushing means furthercomprises a bar with said resilient bristles thereon.

.21. A process for making pile fabrics from a backing and a fibrous web,comprising the following steps:

(a) feeding a backing to a work position on one side of a plurality ofspaced loop formers;

(b) feeding a fibrous web to said work position on the opposite side ofsaid formers;

(c) penetrating said backing between said formers with hooked needlemeans;

(d) pushing fibers from said web onto said hooked needle means in adirection substantially transverse to the direction of movement of saidneedle means;

(e) withdrawing said needle means through said backing to thereby drawbundled loops of said fibers of said web through said backing; and

(f) removing said formers whereby a plurality of spaced longitudinalpleats of said web are held by said backing.

22. A process as set forth in claim 21 further comprising the step ofinterknitting said loops of fibers of said web drawn through saidbacking with each other on the sides of said backing opposite saidlongitudinal pleats.

23. A process as set forth in claim 21-"wherein said fibrous web is fedto said work position at a speed greater than that at which said backingis fed to said work position whereby transverse pleats of said web areformed.

24. A process as set forth in claim 21 wherein said fibrous web is fedto said work position at a rate which is four to ten times the rate atwhich said backing is fed to said work position whereby transversepleats of said web are formed.

25. A process as set forth in claim 21 further comprising the step ofsubjecting a portion of said backing to a shrinkage treatment subsequentto the removal of said formers from said pleats.

26. A process as set forth in claim 21 further comprising the step ofshearing said pleated web to produce a plush surface.

References Cited UNITED STATES PATENTS 271,539 1/1883 Straw. 1,314,5659/1919 Billington 2872.2 1,334,744 3/1920 Farr 16180 2,672,673 3/1954Shaw 2872.2 XR 2,881,505 4/1959 Hoffman 2872.2 2,890,579 6/ 1959Mauersberger. 2,978,786 4/1961 Turner 2872.2 2,993,353 7/1961 Grau 66843,017,847 l/1962 Keen. 3,168,883 2/1965 Ploch et a1. 112411 3,174,3083/1965 Mauersberger 66l92 3,309,901 3/1967 Danhel et a1.

; FOREIGN PATENTS 236,272 7/ 1925 Great Britain. 725,425 3/ 1955 GreatBritain.

ROBERT D. MACKEY, Primary Examiner US. Cl. X.R. 6685

